Method for manufacture of wire reel provided at its ends with corrugated flanges

ABSTRACT

A method for manufacture of wire reel provided at its ends with corrugated flanges utilizing two pairs of rollers and a U-shaped annular body. A metal band is fed between one pair of rollers each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band to form a corrugated band while one side edge of the corrugated band is fed between another pair of rollers each having a smooth surface to deform the corrugated side edge into a flat surface whereby to form an annular corrugated flange. The U-shaped annular body is provided at its one leg portion with an annular projection bent perpendicular thereto. The inner peripheral edge of the corrugated flange is clamped together with the two leg portions of the U-shaped annular body by a press and a drum is secured to the annular projection thus constructing a wire reel.

United States Patent Mizuguchi et al.

METHOD FOR MANUFACTURE OF WIRE REEL PROVIDED AT ITS ENDS WITH CORRUGATED FLANGES Inventors: Toru Mizuguchi; Mitsuo Fujita; Yoshiaki Suzuki, all of Yokohama, Japan Assignees: The Furukawa Electric Company Limited; Toko-Kogyp-Kabushiki Kaisha Filed: Nov. 18, 1970 Appl. No.: 90,697

Foreign Application Priority Data Nov. 19,1969 Japan ..44/92l55 Nov. 19, 1969 Japan... Dec. 26, 1969 Japan ..44/122958 References Cited UNITED STATES PATENTS l/l917 Williams ..113/l16D 3/1939 McCann.. ..29/l59R 51 May 30, 1972 2,152,523 3/1939 McGuire ..29/159 R X 3,108,758 10/1963 Hill ..29/159 X FOREIGN PATENTS OR APPLICATIONS 946,432 8/1956 Germany ..1 13/1 16 D Primary Examiner-John F. Campbell Assistant Examiner-Victor A. Di Palma Attorney-George F. Dvorak, Stephen T. Skrydlak and Marden S. Gordon [57] ABSTRACT A method for manufacture of wire reel provided at its ends with corrugated flanges utilizing two pairs of rollers and a U- shaped annular body. A metal band is fed between one pair of rollers each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band to form a corrugated band while one side edge of the corrugated band is fed between another pair of rollers each having a smooth surface to deform the corrugated side edge into a flat surface whereby to form an annular corrugated flange. The U-shaped annular body is provided at its one leg portion with an annular projection bent perpendicular thereto. The inner peripheral edge of the corrugated flange is clamped together with the two leg portions of the U-shaped annular body by a press and a drum is secured to the annular projection thus constructing a wire reel.

7 Claims, 18 Drawing Figures PATENTEDMAYSO 1912 3,665,588

sum 7 or 7 METHOD FOR MANUFACTURE OF WIRE REEL PROVIDED AT ITS ENDS WITH CORRUGATED FLANGES This invention relates to a method for manufacture of a wire reel provided at its ends with corrugated flanges.

In the past a method has been proposed for the manufacture of a corrugated flange, which comprises feeding a metal band between a female template having a groove which is different in depth in a direction from one edge of the metal band to another edge thereof and a male punch adapted to be engaged with the groove, and moving the male punch into engagement with and disengagement from the female groove intermittently to form a corrugated flange one by one. Such known method, however, has the disadvantage that the method involves not only a long operation time, but also use of a complex and huge installation.

It is, therefore, an object of the invention to obviate the above mentioned disadvantage of the conventional method and provide a novel method by which the corrugated flanges can be formed in a very simple and speedy manner.

A further object of the invention is to assemble the corrugated flanges with a drum in a very simple and rigid manner.

A still further object of the invention is to provide a reinforced wire reel in a very simple and easy manner.

These and other desirable objects are attained, according to the invention, by a method which comprises feeding a metal band between a pair of rollers each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band to form a corrugated band, feeding one side edge of the corrugated band between a pair of rollers each having a smooth surface to deform the corrugated side edge into a flat surface whereby to form an annular corrugated flange, bringing the inner peripheral edge of the corru gated flange into engagement with an annular body which is U-shape in cross section and whose one leg portion is bent perpendicular thereto to form an annular projection, clamping the two leg portions of the U-shaped annular body and the inner peripheral edge of the corrugated flange by means of a press, and connecting a drum to the annular projection, thus constructing a wire reel.

In the invention it is preferable to bend outwardly both leg portions of the U-shaped annular body in a direction perpendicular thereto to form two annular projections, respectively, and connect a drum to one of these two annular projections and connect a reinforcing spider to the other annular projection.

It is also preferable to provide a reinforcing ring made integral with the outer peripheral edge of the corrugated flange or provide a reinforcing ring made as a separate element and connected thereto.

Use may be made of a reinforcing spider in the form of a channel shaped metallic plate or in the form of a cross channel shaped metallic plates.

For a better understanding of the basic idea underlying the invention, the same will be explained by reference to the accompanying drawing, in which like reference numerals denote like parts in the various views, and in which:

FIG. 1 is a fragmentary perspective view illustrating a step of forming a corrugated flange according to the invention;

FIG. 2 is a perspective view of a metal band having a given length;

FIGS. 3, 4 and 5 are perspective views of three embodiments of corrugated flanges;

FIG. 6 is a perspective view of an embodiment of a completed wire reel;

FIG. 7 is a perspective view of an embodiment of a U- shaped annular body;

FIG. 8 is a longitudinal sectional view showing a step of clamping together the corrugated flange shown in FIG. 5 and the U-shaped annular body shown in FIG. 7 by means of a press;

FIG. 9 is a sectional view similar to FIG. 8 but showing the clamped state of the corrugated flange and the U-shaped annular body;

FIG. 10 is a sectional view similar to FIG. 9 but showing the reinforced connection between the corrugated flange and the U-shaped annular body;

FIG. 11 is a perspective view of a modified embodiment of a U-shaped annular body;

FIG. 12 is a perspective view of an embodiment of a reinforcing ring;

FIG. 13 is a sectional view similar to FIG. 8 but showing a step of clamping together the corrugated flange shown in FIG. 3, the U-shaped annular body shown in FIG. 11 and the reinforcing ring shown in FIG. 12 by means of two presses;

FIG. 14 is a sectional view similar to FIG. 13 but showing the clamped state of the corrugated flange, U-shaped annular body and reinforcing ring;

FIGS. 15 and 16 are perspective views of two embodiments of a reinforcing spider;

FIG. 17 is a perspective view similar to FIG. 6 but showing a completed wire reel reinforced by the reinforcing ring shown in FIG. 12 and the spider shown in FIG. 15; and

FIG. 18 is a sectionon line A-A of FIG. 17.

In FIG. 1 a metal band 1 having a suitable width is continuously fed in a direction shown by an arrow between a pair of rollers 2, 2 each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band 1 to form a metal band having corrugations 3. Then, one side edge 4 of the corrugated band is fed between a pair of rollers 5, 5 each having a smooth surface to deform the corrugated side edge 4 into a flat surface. During this step the corrugations 3 at the other side edge 6 become deeper and each ridge 3 separating one corrugation 3 from another approaches to adjacent ridge 3 thereby deforming the corrugated band into an annular form as shown in FIG. 1. Then, that portion of the annular corrugated body which adjoins the straight corrugated portion is cut to obtain a corrugated annular body 7 shown in FIG. 3.

A metal band 1 having a given length as shown in FIG. 2 may be used to obtain the corrugated annular body 7. End edges 8, 8 of the'annular corrugated body 7 may be secured together by welding, etc., to obtain a closed corrugated annular body 7 having a center opening 9 as shown in FIG. 4. In the description hereinafter the corrugated annular bodies 7 shown in FIGS. 3 and 4 will be merely referred to as a corrugated flange.

Then, the outer peripheral edge 4 of the corrugated flange 7 is bent as shown in FIG. 5 to form a reinforcing ring made integral therewith and a drum 10 is connected to the center opening 9 to fonn a wire reel as shown in FIG. 6.

The invention makes use of a U-shaped annular body 11 having two leg portions I2, 12 extending outwardly to form an annular body which is U-shaped in cross section and whose one leg portion 12 is bent perpendicular thereto to form an annular projection 13 as shown in FIG. 7 in order to connect the drum 10 to the center opening 9 of the corrugated flange 7. Then, the inner peripheral edge 6 of the corrugated flange 7 is brought into engagement with the U-shaped annular body 11 as shown in FIG. 8.

The corrugated flange 7 with its open end edges 8 as shown in FIG. 5 may be enlarged in diameter and then brought into engagement with the inner peripheral edge of the U-shaped annular body 11 shown in FIG. 7. Alternatively, a U-shaped annular body with its open end edges may be reduced in diameter and then may be brought into engagement with the inner peripheral edge 6 of the close corrugated flange 7 as shown in FIG. 4.

The assembly of the U-shaped annular body 11 engaged with the corrugated flange 7 is then placed into a press 14 so that the leg portion 12 of the U-shaped annular body 11 and its annular projection 13 are supported by a stationary annular base of the press 14 and that a movable annular press piece 14b abuts against the outer periphery of the leg portion 12' of the U-shaped annular body 11 as shown in FIG. 8. Then, the press 14 is operated to deform the leg portions 12, 12' of the U-shaped annular body 11 so as to bite them in the ridges 3' of the corrugations 3 of the corrugated flange 7 with the result that the corrugated flange 7 is clamped to and made integral with the U-shaped annular body 11 as shown in FIG. 9. Finally, the drum 10 is secured to the annular projections 13 of the U-shaped annular body 1 l to construct a wire reel as shown in FIG. 6.

The wire reel thus constructed may be used as a small-sized wire reel. With a medium-sized wire reel the weight of the wire wound around the drum 10 tends to disconnect the clamped portions so that it is preferable to reinforce several clamped portions by rigidly securing the corrugated flange 7 and the leg portion 12 of the U-shaped annular body 11 by riveting or spot welding as shown in FIGS. 6 and 10. With a large-sized wire reel it is preferable to carry out a projection welding by causing the electric current to flow through the clamped portions simultaneously with the pressing step shown in FIG. 8.

Both leg portions 12, 12 of the U-shaped annular body 11 may be bent outwardly in a direction perpendicular thereto to form two annular projections 13, 13, respectively, and connect the drum 10 to one of the projections 13 and connect a reinforcing spider 21 shown in FIGS. 15 and 16 to the other projection 13.

Instead of making the reinforcing ring integral with the outer peripheral edge 4 of the corrugated flange 7 as shown in FIG. 5, it is preferable to provide a separate reinforcing ring 16 which is U-shaped in cross section and has two leg portions 17, 17' as shown in FIG. 12.

The reinforcing ring 16 with its open end edges 18 may be brought into engagement with the outer peripheral edge 4 of the corrugated flange 7 shown in FIG. 4. Alternatively, a reinforcing ring without having open end edges 18 may be brought into engagement with the outer peripheral edge 4 of the corrugated flange 7 having open end edges 8 shown in FIG. 3 after the latter has been reduced in its diameter. The U-shaped annular body 11 having open end edges 19 is reduced in its diameter and then brought into engagement with the inner peripheral edge 6 of the corrugated flange 7. The inner surface of the leg portion 17 of the reinforcing ring 16 may be secured to the outer peripheral edge 4 of the corrugated flange 7 by welding, etc. If desired, the inner surface of the leg portion 17 of the reinforcing ring 16 may be disposed on the outer peripheral edge 4 of the corrugated flange 7 and the assembly may be secured together by welding, etc.

The assembly constructed as above described is then placed into the press 14 similar to the pressing step as shown in FIG. 8 but in the present embodiment use is made of another press 20 whose stationary annular base 20a and movable annular press piece 20b abut against the leg portions 17 and 17 of the reinforcing ring 16, respectively.

Then, the presses 14 and 20 are simultaneously or successively operated to deform the leg portions 12 and 12' of the U- shaped annular body 11 as described above with reference to FIG. 9 and also bend the leg portion 17' of the reinforcing ring 16 against the outer peripheral edge 4 of the corrugated flange 7, thereby clamping the reinforcing ring 16 to the corrugated flange 7 as shown in FIG. 14.

Finally, the drum 10 and a reinforcing spider 21 shown in FIG. 15 are secured to the annular projections 13 and 13 of the U-shaped annular body 11, respectively, to construct a reinforced wire reel as shown in FIGS. 17 and 18.

The reinforced wire reel thus constructed may be used as a medium-sized wire reel. But, it is preferable to further reinforce the various clamped portions by rigidly securing these portions by riveting or spot welding etc. With a large-sized reinforced wire reel it is preferable to carry outa projection welding by causing the electric current to flow through the clamped portions simultaneously with the pressing step shown in FIG. 13. If desired, a cross reinforcing spider 21 shown in FIG. 16 may be secured to the annular projection 13' of the U- shaped annular body.

The reinforcing spider 21 shown in FIGS. 15 and 16 may be made of a channel shaped metallic plate.

As seen from the above, the invention provides an economical wa of fabricating the corrugated flange, and can be a plied e ectrvely to the fabrication of a wire reel provided at its ends with the corrugated flanges in a simple and speedy manner.

It will be understood that while the invention has been described with reference to preferred embodiments thereof, various changes and modifications may be made all within the full and intended scope of the claims which follow.

What is claimed is:

1. A method for manufacture of a wire reel provided at its ends with corrugated flanges which comprises feeding a metal band between a pair of rollers each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band to form a corrugated band, feeding one side edge of the corrugated band between a pair of rollers each having a smooth surface to deform the corrugated side edge into a flat surface whereby to form an annular corrugated flange, bringing the inner peripheral edge of the corrugated flange into engagement with an annular body which is U-shape in cross section and whose one leg consists of a portion which is bent in a direction perpendicular thereto to form an annular projection, clamping the two legs of the U-shaped annular body and the inner peripheral edge of the corrugated flange together by means of a press, and thereafter connecting a drum to the annular projection, thus constructing a wire reel.

2. A method according to claim 1 wherein portions of the two legs of said U-shaped annular body are bent outwardly in a direction perpendicular thereto to form two annular pro jections, respectively, and then connect a drum to one of these two annular projections and connect a reinforcing spider to the other annular projection.

3. A method according to claim 1 wherein said corrugated flange is provided at its outer peripheral edge with a reinforcing ring made integral therewith.

4. A method according to claim 1 wherein said corrugated flange is provided at its outer peripheral edge with a reinforcing ring made as a separate element and connected thereto.

5. A method according to claim 4 wherein said reinforcing ring made as a separate element is of U-shape in cross section.

6. A method according to claim 2 wherein said reinforcing spider is made of a channel shaped metallic plate.

7. A method according to claim 2 wherein said reinforcing spider is made of cross channel shaped metallic plates.

' 3 665 588- Dated May 30 1972 Patent N Inventor) Toru Mizuguchi et a1 It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

On the cover sheet [73] "T0ko--KogypKahushiki Kaisha" should read Toko Kogyo Kabushiki Keisha Signed and sealed this 6th day of March 1973.

(SEAL) Attest:

EDWARD BLFLETCHER ,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents FORM po'wso H0459) USCOMM-DC Some-pe it U.S, GOVERNMENT PRINTING OFFICE I969 O-J66334, 

1. A method for manufacture of a wire reel provided at its ends with corrugated flanges which comprises feeding a metal band between a pair of rollers each having corrugations on its surface in parallel with its axis arranged perpendicular to the side edges of the metal band to form a corrugated band, feeding one side edge of the corrugated band between a pair of rollers each having a smooth surface to deform the corrugated side edge into a flat surface whereby to form an annular corrugated flange, bringing the inner peripheral edge of the corrugated flange into engagement with an annular body which is U-shape in cross section and whose one leg consists of a portion which is bent in a direction perpendicular thereto to form an annular projection, clamping the two legs of the U-shaped annular body and the inner peripheral edge of the corrugated flange together by means of a press, and thereafter connecting a drum to the annular projection, thus constructing a wire reel.
 2. A method according to claim 1 wherein portions of the two legs of said U-shaped annular body are bent outwardly in a direction perpendicular thereto to form two annular projections, respectively, and then connect a drum to one of these two annular projections and connect a reinforcing spider to the other annular projection.
 3. A method according to claim 1 wherein said corrugated flange is provided at its outer peripheral edge with a reinforcing ring made integral therewith.
 4. A method according to claim 1 wherein said Corrugated flange is provided at its outer peripheral edge with a reinforcing ring made as a separate element and connected thereto.
 5. A method according to claim 4 wherein said reinforcing ring made as a separate element is of U-shape in cross section.
 6. A method according to claim 2 wherein said reinforcing spider is made of a channel shaped metallic plate.
 7. A method according to claim 2 wherein said reinforcing spider is made of cross channel shaped metallic plates. 